Multiple web tension stand

ABSTRACT

A tension station can include a single brake device configured to provide tension to multiple webs, a nip roller configured to nip the multiple webs to a component of the brake device, a tension transducer idler configured to support the multiple webs and to provide tension information indicative of tension of one or more of the multiple webs, and a controller configured to receive the tension information, to compare the tension information to set point information, and to provide a command signal to the brake device;

CLAIM OF PRIORITY AND RELATED APPLICATIONS

This patent application claims the benefit of priority of Osgood, U.S. Provisional Patent Application Ser. No. 62/183,938, entitled “MULTIPLE WEB TENSION STAND,” filed on Jun. 24, 2015 (Attorney Docket No. 4195.004PRV), which is hereby incorporated by reference herein in its entirety.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, which are not necessarily drawn to scale, like numerals may describe similar components in different views. Like numerals having different letter suffixes may represent different instances of similar components. The drawings illustrate generally, by way of example, but not by way of limitation, various embodiments discussed in the present document.

FIGS. 1A-1F illustrate generally various examples of a multiple-web tension station according to the present subject matter.

FIG. 2 illustrates generally an example tension control strategy for a multiple-web tension station.

FIG. 3A-3B illustrates generally details of a dancer assembly for a multiple-web tension station.

FIG. 4 illustrates generally an example multiple-web tension stand according to the present subject matter.

DETAILED DESCRIPTION

Manufacturers of web materials, or tow materials, such as but not limited to, carbon fiber, fiber glass, and other woven pultrusion style processes, rely primarily on passive or manual tension systems for unwind or rewind control do not support separate tension zones (i.e. unwind, process, rewind zones). In certain applications, systems can rely on one motor or drive system to pull material through their entire process. A first method of generating web tension can include using friction forces generated by a tow as it passes by a roller/comb/eyelet to generate a force opposed to the direction of web travel and the rewinding drive. A second method of generating web tension can include a passive braking systems (usually located on a creel) to create holdback force from the rewind drive.

With these methods, it is difficult to establish a constant tension and this causes problems during the weaving process. If the material has too much tension, it can break, fray or become misaligned. If the material is too loose, it causes gaps or unwanted excess material. Either of these can lead to delamination of the final product, cosmetic damage, or structural failures. This is particularly important for carbon fiber as it is increasingly used in high strength applications, such as aerospace technologies, automobiles, offshore drilling, and wind turbines-applications in which material failure can result in significant loss in materials and assets.

The present inventors have recognized apparatus and methods to provide multi-tow average tensioning that can improve the ability to control any number of materials at the same tension value while requiring very little floor space. FIGS. 1A-1F illustrate generally examples of a multiple-web tension station 100 that can include a brake 101, motor or clutch, nip rollers 102, a tension sensing roll 103, a controller 104, one or more idler rollers 106, and a plurality of individual self-adjusting dancer assemblies 105. In certain examples, one of the nip rolls can include a nip actuator assembly 108 to allow engagement and disengagement of at least one of the nip rollers 102. The nip actuator assembly 108 can actuate at least one of the nip rollers 102 to form the nip between the nip rollers 102. In some examples, one or more of the nip rollers 102 can be driven or can be part of a torque generator or brake device. In certain examples, the various rollers and dancers can be mounted between two side plates 107 and the entire multiple-web tension station 100 can be mounted to a machine for a turn-key tension solution. In certain examples, the multiple-web tension station 100 can provide tension simultaneously to a large number of webs 109 in a very small footprint using a single torque generating device, such as a brake 101.

In certain examples, tension (PV) can be transmitted through each web by positively gripping the material with the nip rollers 102. The torque device, such as a brake 101, can be connected directly or through belts/gears to at least one of the nip rollers 102 to form a traction roller or a brake roller which can allow torque to be transmitted to the material. In certain examples, the brake 101 can include a brake pad actuators 121 and a brake disk 122. The tension sensing roll 103 can provide a tension signal representative of web tension on all the webs after the webs pass through the nip rollers 102. In certain examples, the tension signal can be transmitted to the controller 104, which can provide proportional-integral-derivative (PID) control output back to the brake 101 to regulate the system to a desired average tension (SP).

FIGS. 1A-IC illustrate generally a small, modular, multiple-web tension station 100 including two side plates 107 for mechanically mounting the various components and for providing structural rigidity to the station. FIG. 1D illustrates a large, multiple multiple-web tension station 100 including two side plates 107 for mechanically mounting the various components of the station. FIG. 1F illustrates generally a modular, multiple-web tension station having components mounted in a cantilevered fashion to a single side plate 107.

FIG. 2 illustrates generally an example tension control strategy 200 for a multiple-web tension station. The control strategy 200 can include the controller 204, the torque generating device 201, the multiple webs 209 and the tension sensing roll 203. In various examples, the tension sensing roll 203 can include a load cell or other force sensor the can generate an electrical signal responsive to force applied by the multiple webs 209 on the roller mechanism of the tension sensing roll 203. As discussed above, the torque generating device 201 can induce a tension on the multiple webs 209, for example via a brake coupled to a nip roller in which the multiple webs 209 are nipped. The multiple webs 209 can pass over or around a tension transducer 203, such as a tension transducer idler, and the tension transducer 203 can convert the tension exerted by the multiple webs to an electrical feedback signal 240. The electrical feedback signal 240 can provide tension information indicative of the actual tension of the multiple webs 209. The controller 204 can receive a tension set point 241, for example from a user interface, for example, and can compare the tension set point 241 to the feedback signal 240. The controller 204 can then adjust a command signal 242 to the torque generating device 201 based on the comparison of the tension set point 241 and the feedback signal 240 such that the web tension approaches the tension set point 241.

FIG. 3A-3B illustrates generally details of a dancer assembly 305. In certain examples each dancer assembly can include a dancer roller 341 and a dancer actuator 342. The plurality of dancer assemblies can be mounted within a multiple-web tension station using a dancer mount 340 and a dancer actuator mount 343. In certain examples, a plurality of dancer assemblies 305 can be mounted on the dancer mount in close proximity to other dancer assemblies 305. Each dancer assembly 305 can include a dancer actuator 342 coupled to the dancer roller 341 and mounted to the dancer actuator mount 343. In certain examples, the dancer actuator mount 343 can be mounted to one or more side plates (e.g., FIG. 1E; 107) using slots (e.g., FIG. 1E; 110). In certain examples, the side plates 107 can provide a support structure for mechanically mounting various components of the multiple-web tension station 100 in addition to the dancer assemblies, such as, but not limited to, the torque generating device, idler rollers, the tension transducer, the nip actuator assembly, etc. Examples of dancer actuators include, but are not limited to, weights, hydraulic cylinders, pneumatic cylinders, springs, elastic fibers or bands, or combination thereof. For some dancer actuators 342, adjusting the dancer actuator mount 343 can assist in maintaining tension consistency or dancer responsiveness.

In operation, each web path can include interaction with a dancer roller 341. The individual dancer assemblies 305 can allow slight individual tuning to accommodate web discrepancies in elastic and inelastic deformation, travel distance variations, fiber density and quality. The dancer assembly 305 can compensate for these factors with one of several passive methods. In certain examples, the dancer assemblies 305 can be quite small and can be powered by pneumatic cylinders, springs, or dead weight. Any of these methods allow for misalignment between the individual tows. In certain examples, under proper tension control, multiple wens passing through a multiple-web tension station according to the present subject matter can behave as one traditional web of material. In some examples, the dancer assembly 305 can include a position sensor configured to provide position feedback of the dancer roller 341 and the controller can include a dancer position controller configured receive the position feedback and to adjust a force provided by the dancer actuator 342 to maintain a location of the dancer roller 341 in a desired location.

FIG. 4 illustrates generally an example multiple-web tension stand 450 according to the present subject matter. In certain examples, the stand can include a frame 451, leveling feet or casters 452 and one or more multiple-web tension stations 400 as described above. Each multiple-web tension station can include one or more idler rollers 406, a traction or brake roller 462, a tension sensing roll 403, a dancer assembly 405, a nip actuator assembly 408 or combinations thereof. A dancer station can include a dancer roller 441 and a dancer actuator 442. A plurality of dancer assemblies of each multiple-web tension station 400 can be mounted to one or station side plates 407 via a dancer mount 440 or a dancer actuator mount 443. In certain examples, the frame can include one or more additional idler rollers 416 to assist in guiding the plurality of webs 409 through the plurality or multiple-web tension stations 400 of the multiple-web tension stand 450. In certain examples, the one or more of the idler rollers 406, 416, the tension sensing roll 403 and each dancer roller 441 can include grooves to assist in keeping each web guided through the multiple-web tension stand 450. In certain examples, each multiple-web tension station can also include a controller (not shown) and a torque generating device (not shown). In certain examples, the torque generating device can be coupled to the traction or brake roller 462. In some examples, the torque generating device can be coupled to the nip roller 402 of the nip actuator assembly 408.

Existing tension control systems can often require multiple control loops, or at least multiple tension actuators, such as brakes, to regulate multiple webs. Such system can get very expensive and may not be justifiable unless the web material is of extremely high value. The present subject matter can provide very cost effective means, in terms of equipment expense and in terms of machine or system real estate, of controlling multiple webs. For example, a single brake device in a multiple-web tension station can be used to control tension on a large number of webs or tows. This can be extremely relevant as the quantities of webs in some processes can include up to 80 webs or more in some thin web or fiber processes. It is understood that other torque generating devices can include, but are not limited to, pneumatic brakes, electric brakes, hydraulic brakes, motors, magnetic clutches and brakes or combinations thereof.

Additional Notes

In Example 1, a tension station can include a single brake device configured to simultaneously provide tension to multiple webs, a nip roller configured to nip the multiple webs to a component of the brake device, a tension transducer idler configured to support the multiple webs and to provide tension information indicative of tension of one or more of the multiple webs, and a controller configured to receive the tension information, to compare the tension information to set point information, and to provide a command signal to the brake device;

In Example 2, the tension station of Example 1 optionally includes a first side plate configured to mechanically support the brake device, the nip roller and the tension transducer.

In Example 3, the tension station of any one or more of Examples 1-2 optionally includes a plurality of dancer assemblies configured to accommodate tension variations of the multiple webs, wherein each web of the multiple webs is associated with a single dancer assembly of the plurality of dancer assemblies.

In Example 4, the tension station of any one or more of Examples 1-2 optionally includes a dancer mount mechanically coupled to the first side plate, wherein the plurality of dancer assemblies are mounted directly to the dancer mount.

In Example 5, each dancer assembly of any one or more of Examples 1-4 optionally includes a dancer roller configured to support a web of the multiple webs and a dancer actuator coupled to the dancer roller, the dancer actuator configured to support movement of the dancer roller in response to tension fluctuations of the web.

In Example 6, the dancer roller of any one or more of Examples 1-5 optionally includes a groove configured to receive the web.

In Example 7, the dancer assembly of any one or more of Examples 1-6 optionally includes a position sensor configured to provide position feedback of the dancer roller, and the controller of any one or more of Examples 1-6 optionally includes a dancer position controller configured receive the position feedback and to adjust a force provided by the dancer actuator to maintain a position of the dancer roller in a desired location.

In Example 8, the tension station of any one or more of Examples 1-2 optionally includes a second side plate opposite the first side plate and configured to mechanically support the brake device, the nip roller and the tension transducer and the multiple webs are configured to pass between the first side plate and the second side plate.

In Example 9, the single brake device of any one or more of Examples 1-8 optionally includes a torque generator coupled to a torque roller.

In Example 10, the torque generator of any one or more of Examples 1-9 optionally includes a brake.

In Example 11, the torque generator of any one or more of Examples 1-10 optionally includes a clutch.

In Example 12, the torque generator of any one or more of Examples 1-11 optionally includes a motor.

In Example 13, the tension station of any one or more of Examples 1-12 optionally include a pneumatic nip actuator configured to move the nip roller to engage and to disengage contact with the torque roller.

In Example 14, the tension control station of any one or more of Examples 1-13 optionally is configured to simultaneously control tension on more than 10 webs.

In Example 15, a multiple-web tension stand can include a stand frame configured to receive and pass multiple webs, a plurality of multiple-web tension stations mounted to the stand frame. Each multiple-web tension station of the plurality of multiple-web tension stations can include a single brake device configured to provide tension to a plurality of webs of the multiple webs, a nip roller configured to nip the plurality of webs to a component of the brake device, a tension transducer idler configured to support the plurality webs and to provide tension information indicative of tension of one or more webs of the plurality of webs, and a controller configured to receive the tension information, to compare the tension information to set point information, and to provide a command signal to the single brake device.

In Example 16, each multiple-web tension station of any one or more of Examples 1-15 optionally includes a first side plate configured to mechanically support the single brake device, the nip roller and the tension transducer.

In Examples 17, each multiple-web tension station of any one or more of Examples 1-16 optionally includes a plurality of dancer assemblies configured to accommodate tension variations of the plurality of webs, wherein each web of the plurality of webs is associated with a single dancer assembly of the plurality of dancer assemblies.

In Example 18, each dancer assembly of any one or more of Examples 1-17 optionally includes a dancer roller configured to support a web of the plurality of webs, and a dancer actuator coupled to the dancer roller, the dancer actuator configured to support movement of the dancer roller in response to tension fluctuations of the web.

In Example 19, each multiple-web tension station of any one or more of Examples 1-18 optionally includes a second side plate opposite the first side plate and configured to mechanically support the brake device, the nip roller, the tension transducer idler, and the plurality of dancer assemblies, and the plurality of webs are configured to pass between the first side plate and the second side plate.

In Example 20, the multiple webs of any one or more of Examples 1-19 optionally include at least 80 webs.

A system or apparatus can include, or can optionally be combined with any portion or combination of any portions of any one or more of the examples or illustrations above to include, means for performing any one or more of the functions described above, or a machine-readable medium including instructions that, when performed by a machine, cause the machine to perform any one or more of the functions described above.

The above detailed description includes references to the accompanying drawings, which form a part of the detailed description. The drawings show, by way of illustration, specific embodiments in which the invention can be practiced. These embodiments are also referred to herein as “examples.” Such examples can include elements in addition to those shown or described. However, the present inventor also contemplates examples in which only those elements shown or described are provided. Moreover, the present inventor also contemplates examples using any combination or permutation of those elements shown or described (or one or more aspects thereof), either with respect to a particular example (or one or more aspects thereof), or with respect to other examples (or one or more aspects thereof) shown or described herein.

All publications, patents, and patent documents referred to in this document are incorporated by reference herein in their entirety, as though individually incorporated by reference. In the event of inconsistent usages between this document and those documents so incorporated by reference, the usage in the incorporated reference(s) should be considered supplementary to that of this document, for irreconcilable inconsistencies, the usage in this document controls.

In this document, the terms “a” or “an” are used, as is common in patent documents, to include one or more than one, independent of any other instances or usages of “at least one” or “one or more.” In this document, the term “or” is used to refer to a nonexclusive or, such that “A or B” includes “A but not B,” “B but not A,” and “A and B,” unless otherwise indicated. In this document, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Also, in the following claims, the terms “including” and “comprising” are open-ended, that is, a system, device, article, or process that includes elements in addition to those listed after such a term in a claim are still deemed to fall within the scope of that claim. Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects.

Method examples described herein can be machine or computer-implemented at least in part. Some examples can include a computer-readable medium or machine-readable medium encoded with instructions operable to configure an electronic device to perform methods as described in the above examples. An implementation of such methods can include code, such as microcode, assembly language code, a higher-level language code, or the like. Such code can include computer readable instructions for performing various methods. The code may form portions of computer program products. Further, in an example, the code can be tangibly stored on one or more volatile, non-transitory, or non-volatile tangible computer-readable media, such as during execution or at other times. Examples of these tangible computer-readable media can include, but are not limited to, hard disks, removable magnetic disks, removable optical disks (e.g., compact disks and digital video disks), magnetic cassettes, memory cards or sticks, random access memories (RAMs), read only memories (ROMs), and the like.

The above description is intended to be illustrative, and not restrictive. For example, the above-described examples (or one or more aspects thereof) may be used in combination with each other. Other embodiments can be used, such as by one of ordinary skill in the art upon reviewing the above description. The Abstract is provided to comply with 37 C.F.R. §1.72(b), to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Also, in the above Detailed Description, various features may be grouped together to streamline the disclosure. This should not be interpreted as intending that an unclaimed disclosed feature is essential to any claim. Rather, inventive subject matter may lie in less than all features of a particular disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separate embodiment, and it is contemplated that such embodiments can be combined with each other in various combinations or permutations. The scope of the invention should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. 

What is claimed is:
 1. A tension station comprising: a single brake device configured to simultaneously provide tension to multiple webs; a nip roller configured to nip the multiple webs to a component of the brake device; a tension transducer idler configured to support the multiple webs and to provide tension information indicative of tension of one or more of the multiple webs; and a controller configured to receive the tension information, to compare the tension information to set point information, and to provide a command signal to the brake device;
 2. The tension station of claim 1, including a first side plate configured to mechanically support the brake device, the nip roller and the tension transducer.
 3. The tension station of claim 2, including a plurality of dancer assemblies configured to accommodate tension variations of the multiple webs, wherein each web of the multiple webs is associated with a single dancer assembly of the plurality of dancer assemblies.
 4. The tension station of claim 3, including a dancer mount mechanically coupled to the first side plate, wherein the plurality of dancer assemblies are mounted directly to the dancer mount.
 5. The tension station of claim 3, wherein each dancer assembly includes: a dancer roller configured to support a web of the multiple webs; and a dancer actuator coupled to the dancer roller, the dancer actuator configured to support movement of the dancer roller in response to tension fluctuations of the web.
 6. The tension station of claim 5, wherein the dancer roller includes a groove configured to receive the web.
 7. The tension station of claim 3, wherein the dancer assembly includes a position sensor configured to provide position feedback of the dancer roller; and wherein the controller includes a dancer position controller configured receive the position feedback and to adjust a force provided by the dancer actuator to maintain a position of the dancer roller in a desired location.
 8. The tension station of claim 2, including a second side plate opposite the first side plate and configured to mechanically support the brake device, the nip roller and the tension transducer; and wherein the multiple webs are configured to pass between the first side plate and the second side plate.
 9. The tension station of claim 1, wherein the single brake device includes a torque generator coupled to a torque roller.
 10. The tension station of claim 9, wherein the torque generator includes a brake.
 11. The tension station of claim 9, wherein the torque generator includes a clutch.
 12. The tension station of claim 9, wherein the torque generator includes a motor.
 13. The tension station of claim 1, including a pneumatic nip actuator configured to move the nip roller to engage and to disengage contact with the torque roller.
 14. The tension station of claim 1, wherein the tension control station is configured to simultaneously control tension on more than 10 webs.
 15. A multiple-web tension stand comprising: a stand frame configured to receive and pass multiple webs; a plurality of multiple-web tension stations mounted to the stand frame; and wherein each multiple-web tension station of the plurality of multiple-web tension stations includes: a single brake device configured to provide tension to a plurality of webs of the multiple webs; a nip roller configured to nip the plurality of webs to a component of the brake device; a tension transducer idler configured to support the plurality webs and to provide tension information indicative of tension of one or more webs of the plurality of webs; and a controller configured to receive the tension information, to compare the tension information to set point information, and to provide a command signal to the single brake device.
 16. The tension stand of claim 15, wherein each multiple-web tension station includes a first side plate configured to mechanically support the single brake device, the nip roller and the tension transducer.
 17. The tension stand of claim 16, wherein each multiple-web tension station includes a plurality of dancer assemblies configured to accommodate tension variations of the plurality of webs, wherein each web of the plurality of webs is associated with a single dancer assembly of the plurality of dancer assemblies.
 18. The tension stand of claim 17, wherein each dancer assembly includes: a dancer roller configured to support a web of the plurality of webs; and a dancer actuator coupled to the dancer roller, the dancer actuator configured to support movement of the dancer roller in response to tension fluctuations of the web.
 19. The tension stand of claim 17, wherein each multiple-web tension station includes a second side plate opposite the first side plate and configured to mechanically support the brake device, the nip roller, the tension transducer idler, and the plurality of dancer assemblies; and wherein the plurality of webs are configured to pass between the first side plate and the second side plate.
 20. The tension stand of claim 15, wherein the multiple webs include at least 80 webs. 